Intelligent well sand control

ABSTRACT

A sand control assembly having individual single zone flow control for a multizone hydrocarbon well having remote control capability. Flow control in individual zones and superior packing are achieved.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of an earlier filing datefrom U.S. Provisional Application Serial No. 60/280,587 filed Apr. 2,2001, the entire disclosure of which is incorporated herein byreference.

BACKGROUND

[0002] 1. Technical Field

[0003] The disclosure relates to oil field gravel pack systems andmethods for their use. More particularly, the disclosure relates tomultiple sand control assemblies with single zone control.

[0004] 2. Prior Art

[0005] Sand control apparatus, systems and methods have been animportant part of wells for hydrocarbon production for an extendedperiod and are used to support boreholes in unconsolidated formations aswell as to cause particulate matter (such as sand) entrained inproduction fluid to bridge at the sand control assembly and thus beexcluded from the tubing of the well. Unfortunately prior art sandcontrol assemblies, in order to obtain individual zone control employ aninner assembly which reduces the I.D. of the string available for otherpurposes. Without the inner assembly individual zonal control is notpossible.

SUMMARY

[0006] Multizone sand control assemblies with flow control forindividual zones can be achieved while maintaining a full bore I.D. ofthe sand control assembly. The sand control assemblies that make therealization of these benefit possible comprise individual componentsthat are commercially available but which have not heretofore beencombined. The effect of the combination as taught herein is synergisticand produces results of significant benefit to the art such as thementioned individual control whether the control is for productionfluids or remediation fluids; and in one embodiment produces superiorgravel packing. The assembly includes a string of spaced apart packers,with a sump packer at a most downhole location for the string. Thepackers are interspersed by gravel pack screen sections and slidingsleeves (the number of sleeves depends upon the embodiment). Inaddition, a blank pipe section is located radially inwardly of eachscreen section in both of the discussed embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Referring now to the drawings wherein like elements are numberedalike in the several Figures:

[0008]FIGS. 1 and 2 is an elongated view in quarter section of a gravelpack flow control assembly; and

[0009]FIGS. 3 and 4 is an alternate elongated view in quarter section ofa gravel pack flow control assembly.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0010] Two embodiments are disclosed herein which provide control in amultizone sand control assembly. Control is with respect to fluidsflowing into the well through individual or selective groups of zonesand for sealing off selected zones during remediation treatment to avoiddamaging or contaminating zones not in need of remediation.Consequently, such control also alleviates the unnecessary loss ofexpensive remediation fluids which in some prior art systems areneedlessly and profitlessly lost into the formation. In addition, forone of the embodiments discussed herein, the control gained by theparticular assemblies discussed enhances an active gravel packingprocedure by alleviating bridging otherwise caused by rapid“dehydration” of the gravel pack slurry (usually gravel and a liquidcarrier) to the formation. The use of either of the assemblies describedherein preferably follows conventional perforating and fracturingoperations. In each embodiment, recirculation of excess proppant out ofthe well after fracturing is preferred.

[0011] In a first embodiment, referring to FIGS. 1 and 2, a multiplezone sand control assembly 10 is illustrated with three zones 12 a, 12 band 12 c. A sump packer 14 is located at a downhole end of the assembly10 as illustrated. Sump packer 14, in one embodiment, is installed inthe well in a distinct run on preferably wireline to facilitatedeployment in a desired location. Alternatively, sump packer 14 could bemade a part of assembly 10. Assembly 10 is otherwise installed as asingle assembly in one run in the hole. Where sump pump 14 is installedin a separate run, assembly 10 is stabbed into sump packer 14 withlocator tubing seal assembly 16. Preferably assembly 10 is constructedat a surface location with spacing sufficient to locate a plurality ofscreens included therein proximate perforations 18 in casing 20 whichwere created in the perforating operation.

[0012] Locator tubing seal assembly 16 is connected to a valve 22,preferably an intelligent production regulator (IPR) valve commerciallyavailable from Baker Oil Tools, Houston, Texas. IPR valves preferablycomprise a valve for regulating flow of a fluid in addition to pressuresensors. One pressure sensor is located upstream of the valve and onepressure sensor is located downstream of the valve. IPR valve 22 isconnected through a shroud 24 and sliding sleeve 26 to a bypass packoffsub 28 having a flow conduit 30 therein which communicates with annularspace 32 between shroud 24 and sleeve 26. Radially inwardly and sealedto sub 28 is tubing 34. Tubing 34 is preferably sealed to sub 28 withone or more O-rings 36. Connected at an uphole end of sub 28 iscrossover sub 38 having pin and box threads at downhole and uphole endsthereof, respectively.

[0013] Crossover sub 38 is connected at its uphole end to a screen 40.It should be noted that between screen 40 and tubing 34 is defined anannular flow area 42, which area is fluidly connected to conduit 30 insub 28 and thereby to annular space 32. Fluid flowing in the spacesdefined is conveyable to an I.D. 43 of the pack assembly 10 through oneor more flow ports 44 controlled by IPR valve 22 via sleeve 46. Itshould further be noted that such flow may also be conveyed to the I.D.43 of pack assembly 10 through one or more ports 48 in sliding sleeve 26controlled by manually operable sleeve 50 which generally would be usedin the event IPR valve 22 did not function as intended.

[0014] Referring back to screen 40 and tubing 34, both elements arepreferably connected at an uphole end thereof to double pin sub 52 whichin turn is connected to a blank pipe section 54. Blank pipe section 54is connected to a retrievable packer 56.

[0015] Each of the ensuing uphole portions of sand control assembly 10bear similar numerals (one hundred and two hundred series of the samenumbers) since the individual components illustrated are identical tothose described above.

[0016] A preferred concise procedure for installation of theabove-discussed embodiment is as follows:

[0017] 1. Set sump packer below planned lower zone perforations.

[0018] 2. Perforate lower zone.

[0019] 3. Perform hydraulic fracture treatment in lower zone.

[0020] 4. Leave sand plug across lower zone and perforate middle zone.

[0021] 5. Perform hydraulic fracture treatment in middle zone.

[0022] 6. Leave sand plug across middle zone and perforate upper zone.

[0023] 7. Perform hydraulic fracture treatment in upper zone.

[0024] 8. Wash sand out of casing using PERFFLOW pills as required tocontrol fluid loss.

[0025] 9. Run isolation packers, screens and IPR valves as illustratedwith valves closed.

[0026] 10. Stab into sump packer and pressure tubing to set isolationpackers.

[0027] 11. Open IPR valves and bring well on production (frac sand willflow back and fill annulus between screen and casing).

[0028] Assembly 10, having been installed in a well casing 20 after afracturing and a recirculation cleanout procedure, is intended toreceive a natural gravel pack. As one of skill in the art willrecognize, many thousands of pounds of proppant (usually sand or gravel)is pumped into perforation zones in a well for the fracturing operation.Thus, far more than a sufficient quantity of proppant exists adjacentperforations 18 and in perforations 18 after the recirculating clean outof the well to satisfy the need for proppants in a “natural gravel pack”operation. Once assembly 10 is set, IPR valve 22 is opened and the wellis allowed to flow. By the action of this flow, proppants left in theperfs 18 and in the vicinity thereof and which are not proppingfractures open are driven toward screen 40 where they are “dehydrated”against the screen while wellbore fluids pass therethrough. Proppantscontinue to be drawn to the screen and in the direction of gravity tothe next packer until the annular space 58 between packer 56 and sumppacker 14 is filled with proppant. The wellbore fluid flowing throughscreen 40 is conveyed via annular flow area 42 through conduit 30 toannular space 32 and through port 44, preferentially, or port 48 intoassembly I.D. 43 and to an uphole location. This is the condition inwhich the zone will operate during normal well production, however inorder to facilitate natural gravel packing of the other zones 12 b, 12 c(two illustrated but not so limited), IPR valve 22 is preferably closed.The process for zone 12 b begins as did the process for zone 12 a withthe opening of an IPR valve 122 (one hundred series of same numerals).Upon completion of the natural gravel packing operation of zone 12 b asimilar process will preferably occur in zone 12 c and so on for anyremaining zones.

[0029] Subsequent to the natural gravel packing operation, one or moreof the IPR valves 22, 122, 222 may be opened to produce the well. Itshould be noted that each of the IPR valves is preferably addressableand operable from a remote location.

[0030] Facilitating remote location actuation is preferably a TEC(tubing encapsulated conductor) 60 extending from the remote location toeach IPR valve. Of course it will be appreciated that other means ofcommunicating with the IPR valves remotely can be substituted such asbut not limited to fiber optic conductors hydraulic line, etc.

[0031] The assembly 10 affords control in each zone of a multizonal sandcontrol assembly individually, collectively or in any combination topromote or hinder production from that zone. Additionally, thecapability of remotely controlling each zone allows for controlling theloss of expensive fluids intended to have an effect on one or more zonesbut not others. Moreover, remote control allows for protection of theperforations from harmful remediation activities needed in one or morebut not all zones. Furthermore, the embodiment maintains a full boreI.D. of the assembly 10 which facilitates both higher production ratecapability and allows larger tools or strings to pass through theassembly 10 to or from more downhole locations.

[0032] In another embodiment, referring to FIGS. 3 and 4, a frac andpack assembly 310 is illustrated. Since the great majority of componentsof assembly 310 are common to the embodiment of FIGS. 1 and 2, the threehundred, four hundred and five hundred series numerals thereon willsuffice in combination with the foregoing explanation to explain theportions of the assembly not specifically addressed in the paragraphssubsequent hereto.

[0033] The embodiments of FIGS. 3 and 4 differ from the foregoingembodiment in areas bounded by double pin sub 352 and blank pipe 354.The distinction is the interconnection of additional blank pipe 362 andsliding sleeve 364 having port 366 and manually actuatable sleeve 368.Sleeve 368 is actuable by a conventional crossover tool (not shown).

[0034] In keeping with the foregoing information, the following is aconcise list of procedures for installing the second embodimentdiscussed herein. Operations relevant to the assembly 310 are furtherdiscussed hereunder. The concise procedure is as follows:

[0035] 1. Set sump packer below planned lower zone perforations.

[0036] 2. Perforate lower zone.

[0037] 3. Perform hydraulic fracture treatment in lower zone.

[0038] 4. Leave sand plug across lower zone and perforate middle zone.

[0039] 5. Perform hydraulic fracture treatment in middle zone.

[0040] 6. Leave sand plug across middle zone and perforate upper zone.

[0041] 7. Perform hydraulic fracture treatment in upper zone.

[0042] 8. Wash sand out of casing using PERFFLOW pills as required tocontrol fluid loss.

[0043] 9. Run isolation packers, screens and IPR valves as illustratedwith valves closed.

[0044] 10. Stab into sump packer and pressure tubing to set isolationpackers.

[0045] 11. Run crossover tool with selective shifting tool on coiledtubing and open lower CMD sliding sleeve.

[0046] 12. Position crossover tool across lower CMD sliding sleeve.

[0047] 13. Open lower IPR valve and circulate gravel pack intoscreen/casing annulus until screenout.

[0048] 14. Pick-up crossover tool and circulate out excess gravel.

[0049] 15. Pull out of hole with crossover tool and close lower CMDsliding sleeve and IPR.

[0050] 16. Run crossover tool with selective shifting tool on coiledtubing and open middle CMD sliding sleeve.

[0051] 17. Position crossover tool across middle CMD sliding sleeve.

[0052] 18. Open middle IPR valve and circulate gravel pack intoscreen/casing annulus until screenout.

[0053] 19. Pick-up crossover tool and circulate out excess gravel.

[0054] 20. Pull out of hole with crossover tool and close middle CMDsliding sleeve and IPR.

[0055] 21. Run crossover tool with selective shifting tool on coiledtubing and open upper CMD sliding sleeve.

[0056] 22. Position crossover tool across upper CMD sliding sleeve.

[0057] 23. Open upper IPR valve and circulate gravel pack intoscreen/casing annulus until screenout.

[0058] 24. Pick-up crossover tool and circulate out excess gravel.

[0059] 25. Pull out of hole with crossover tool and close upper CMDsliding sleeve and IPR.

[0060] 26. Open IPR valves and bring well on production.

[0061] Assembly 310, like assembly 10, is run in the hole and setsubsequent to perforating and fracturing operations as well asrecirculating cleanout of proppants left in the I.D. of casing 20. Thesand control operation in this embodiment however includes an activegravel packing operation in that a gravel slurry is directed intoannulus 58 through the crossover tool having had its discharge port (notshown) aligned with port 366 in sliding sleeve 364. IPR valve 322 isopened and gravel laden slurry is propagated toward screen 340 throughport 366 from the crossover tool (not shown). Upon reaching screen 340and particularly starting at a downhole end of screen 340, gravel orother sand control material is “dehydrated” due to the carrier fluidbeing drawn off through screen 340 to annular flow area 358, throughfluid conduit 330 to annular space 332 through port 344 preferentiallyor port 348 secondarily to assembly 310, I.D. 343 for delivery back tothe crossover sub and to an uphole location. Gravel packing continuesuntil a pressure drop downhole of the screen or pressure spike uphole ofthe screen is detected. Pressure conditions are detectable by the IPRvalve using sensors as indicated above and/or by an additional sensorlocated preferably uphole of the sliding sleeve 364 and downhole of thezones uphole defining packer 356, 456 and 556. A sensor is schematicallyillustrated in FIGS. 3 and 4 and is numbered 370, 470 and 570 in therespective zones. Upon detected pressure change, pumping of the slurryis halted. The following action of pulling the crossover tool uphole tothe next zone closes sleeve 368. IPR valve 322 is also preferably closedto completely seal off zone 312 while packing operations proceed inzones 312 b and 312 c sequentially. It should be noted that thisembodiment, as in the foregoing embodiment, maintains a full bore I.D.of the gravel pack assembly 310 which allows for higher flow rates ofsand control pack carrying fluid back to an uphole location than waspossible in the prior art due to a restricted diameter return flow tube.This creates a better gravel pack by avoiding potential bridging causedby slurry flowing out to the reservoir faster than it could move up thereturn. In addition this embodiment is endowed with the beneficialfeatures of the foregoing embodiment including remote control.

[0062] While preferred embodiments of the invention have been shown anddescribed, various modifications and substitutions may be made theretowithout departing from the spirit and scope of the invention.Accordingly, it is to be understood that the present invention has beendescribed by way of illustration and not limitation.

What is claimed:
 1. A sand control assembly in a well comprising: ascreen; a valve disposed downhole of said screen; a packer disposeduphole of said screen; a sump packer disposed downhole of said valve. 2.A sand control assembly as claimed in claim 1 wherein said screenfurther includes blank tubing disposed radially inwardly of said screenand in spaced relationship with said screen to define an annular flowarea between said tubing and said screen.
 3. A sand control assembly asclaimed in claim 2 wherein said annular flow area is fluidly connectedto said valve.
 4. A sand control assembly as claimed in claim 3 whereina fluid flowing in said annular flow area is conveyable through saidvalve to an I.D. of said assembly.
 5. A sand control assembly as claimedin claim 1 wherein said valve is remotely controlled.
 6. A sand controlassembly as claimed in claim 1 wherein said assembly further comprises aflow control device located between said packer and said screen.
 7. Asand control assembly as claimed in claim 6 wherein said flow controldevice is receptive to through flow of a slurry material from acrossover tool disposed thereat.
 8. A sand control assembly as claimedin claim 1 wherein said gravel pack assembly includes a plurality ofsaid screen, said valve and said packer.
 9. A sand control assembly asclaimed in claim 6 wherein said gravel pack assembly includes aplurality of said screen, said valve and said packer.
 10. A sand controlassembly as claimed in claim 1 wherein said valve is an IPR valve.
 11. Asand control assembly as claimed in claim 10 wherein said IPR valveincludes at least one sensor.
 12. A sand control assembly in a wellcomprising: installing the gravel pack assembly of claim 1; opening saidvalve; and producing the well.
 13. A method for sand control comprising:installing the sand control assembly of claim 6; running a crossovertool into the well and opening said flow control device; opening saidvalve; pumping a slurry into said sand control assembly through saidflow control device and back to a remote location through said valve.14. A method for sand control as claimed in claim 13 wherein said methodfurther comprises closing said flow control device with said crossovertool.
 15. A method for sand control as claimed in claim 13 wherein saidmethod further comprises closing said valve remotely.
 16. A method forsand control as claimed in claim 13 wherein said method includes sensinga wellbore parameter related to sand control.
 17. A method for sandcontrol as claimed in claim 13 wherein said method further includessensing pressure, at least one of upstream of said valve and downstreamof said valve.
 18. A method for sand control as claimed in claim 17wherein said method further includes sensing pressure upstream of saidscreen.